Apparatus for thermal processing of raw material in meal form

ABSTRACT

Cement clinker production apparatus having a precalcination stage connected upstream of a rotary kiln, in which precalcination stage a CO-containing reduction zone in the rotary kiln off-gas duct is employed for the purpose of reducing the pollutant NO x . In order to make certain that the quantitative ratio of O 2  in the rotary kiln off-gas to fuel admitted by a deNO x  burner, and thus control the effectiveness of NO x  reduction, a pivoting throttle valve ( 33 ) is positioned in the precalcination stage to control the quantity of rotary kiln off-gas and thus the O 2  content in the kiln off-gas. The throttle valve ( 33 ) is positioned in the rotary kiln off-gas duct ( 15 ) above the deNO x  burner ( 19 ), above the raw meal inlet ( 13 ), and before the confluence of the tertiary air substream with the rotary kiln off gas. The throttle valve ( 33 ) is pivotable about an articulation ( 34 ) at the bottom side of the valve so that the flow of the rotary kiln offgas remains laminar, thus enhancing the reaction length of the CO-containing reduction zone ( 23 ).

[0001] This invention relates to an apparatus for thermal processing of raw materials in meal form, particularly in the production of cement clinker from raw meal, having raw meal preheater, precalcination stage, rotary kiln and clinker cooler, according to the preamble of Claim 1.

[0002] In apparatuses for the production of cement clinker from cement raw meal, in order to avoid uneconomically long and/or large in diameter rotary kilns and to hold down the specific heat requirement of the cement clinker production process, it is known to connect upstream of the rotary kiln, as viewed in the material flow direction, a precalcination stage, which is equipped with at least one secondary firing (besides the firing in the rotary kiln). In a known precalcination stage, the rotary kiln off-gas riser supplied with fuel and preheated raw meal, or the gas-solids suspension contained therein is diverted by 90° (U.S. Pat. No. 4,080,218) or by 180° (EP-B-0 222 044) and admitted to the lowermost cyclone of the cyclone suspension preheater system in order to separate the precalcined raw meal from the gas stream. Along with the requirement of the highest possible quality precalcination of the cement raw meal before admission to the rotary kiln, the builders and operators of cement clinker production lines are being confronted at the same time with more stringent requirements as to low emission values for pollutants such as NO_(x) and CO.

[0003] In the known precalcination stages, the rotary kiln off-gas is combined with at least one substream of tertiary air coming from the clinker cooler before admission to the lowermost cyclone of the cyclone suspension heat exchanger. Before this combining, the fuel admitted to the rotary kiln off-gas riser is combusted in richer than stoichiometric fashion, that is, with a deficiency of oxygen, in order to establish a CO-containing reduction zone or CO gas strands for the reduction of the pollutant NO_(x), which is formed particularly by high-temperature combustion in the rotary kiln (thermal NO_(x)), while the fuel admitted to the adjacent tertiary air duct is combusted in leaner than stoichiometric fashion, that is, with an excess of oxygen (EP-B-0 222 044). The CO not consumed in the NOx reduction zone of the rotary kiln off-gas duct, as well as any solid fuel particles not initially combusted in the precalcination stage, are then, downstream as viewed in the direction of suspension flow, subjected to secondary combustion with excess oxygen from the tertiary air duct, this residual burnout being promoted by the gooseneck-shaped 180° diversion of the suspension flow in the precalcination stage.

[0004] In the known precalcination stages, the effectiveness of the CO-containing reduction zone formed in the rotary kiln off-gas duct depends on the O₂ content of the rotary kiln off-gas in relation to the quantity of fuel admitted via the at least one DeNO_(x) burner. It is understood that this ratio cannot be accurately adjusted by control action on the induced-draft fan that is connected downstream, as viewed in the direction of off-gas flow, of the cyclone suspension heat exchanger system, because, aside from the rotary kiln off-gas, this induced-draft fan simultaneously takes in and exhausts the tertiary air as well. This ratio also cannot be exactly controlled by building an air choke into the tertiary air line in the precalcination stage before the confluence of the tertiary air line into the rotary kiln off-gas duct (DE-A-35 22 272, FIG. 1).

[0005] It has also been proposed already (e.g., DE-A-197 32 778, FIG. 6) that a baffle be built into the rotary kiln off-gas riser in a cement clinker production line below the raw meal inlet, which baffle, because of the severe mechanical/thermochemical stress it experiences, is subject to severe wear and therefore is designed as a plate-shaped hollow body through which coolant flows. Its cooling does prolong the service life of the known baffle; if, however, it were built into the CO-containing reduction zone or in the CO-containing gas strands of a rotary kiln off-gas duct equipped with DeNO_(x) burner, it would introduce turbulence into the laminar character of the gas-solids suspension by vortex formation and thus in undesirable fashion shorten the length of the CO-containing reduction zone, shorten the residence times associated therewith, and ultimately impair the effectiveness of the NO_(x) decomposition reaction.

[0006] In systems for cement clinker production of the above-described kind, having a precalcination stage connected upstream of the rotary kiln, in which precalcination stage a CO-containing reduction zone in the rotary kiln off-gas duct is employed to reduce the pollutant NO_(x), it is an object of the invention to make certain that the quantitative ratio of O₂ in the rotary kiln off-gas to fuel admitted via DeNO_(x) burner, and thus the effectiveness of NO, reduction, can be purposely controlled.

[0007] According to the invention, this object is achieved with an apparatus having the features of Claim 1. Advantageous developments of the invention are identified in the dependent Claims.

[0008] For the purpose of diminishing NO, in the rotary kiln off-gas in the cement clinker production line according to the invention, with the precalcination stage having at least one DeNO_(x) burner with rich fuel combustion in the rotary kiln off-gas duct, the effectiveness of the CO-containing reduction zone is not only influenced indirectly by the adjustment of air chokes that can be built into the tertiary air lines coming from the clinker cooler before their confluence into the rotary kiln off-gas duct, and/or by the adjustment of the induced-draft fan that simultaneously exhausts the rotary kiln off-gas and the tertiary air, but according to the invention the fuel-to-oxygen ratio at the DeNO_(x) burner and thus the effectiveness of the CO-containing reduction zone is directly controlled by building a throttle valve into the rotary kiln off-gas duct above the DeNO_(x) burner and above the raw meal inlet but before or below the confluence of a tertiary air stream, which throttle valve directly controls the quantity of rotary kiln off-gas and thus the O₂ content in the kiln off-gas and thus the CO content in the CO-containing reduction zone.

[0009] As the O₂ content in the rotary kiln off-gas rises, the throttle valve built into the rotary kiln off-gas duct here is placed in pivoted positions that more strongly throttle the rotary kiln off-gas stream, and conversely. When the rotary kiln off-gas is throttled, its O₂ content decreases, and if the quantity of DeNO, fuel is unchanged, the CO content in the CO-containing reduction zone increases, and conversely. Thus the O₂ content in the rotary kiln off-gas, measured in suitable fashion in the rotary kiln inlet chamber, can lie in a range of roughly 1.0% to 3.0%, and the CO content in the CO-containing reduction zone and thus the efficiency of this zone can be controlled in comparatively accurate fashion.

[0010] The throttle valve built into the rotary kiln off-gas duct has its pivoting range in the flow direction of the off-gas, that is, the throttle valve articulation is arranged on the bottom side of the valve, on which the off-gas impinges. Within its pivoting range, the throttle valve thus stands perpendicularly to obliquely upwardly. In this way, the character of the flow of rotary kiln off-gas remains laminar in all pivoted positions of the throttle valve, and the length of the CO-containing reduction zone or, respectively, CO-containing strands of off-gas and thus also the residence time of the reactants in this CO-containing cloud remain as long as possible. Furthermore, disturbing material accretions due to flow separations at the throttle valve do not occur.

[0011] The service life of the throttle valve in the rotary kiln off-gas, which can have a temperature of approximately 800 to 900° C. after the introduction of the raw meal to be calcined, is further increased if, according to a further feature of the invention, the throttle valve is designed as a plate-shaped hollow body through which a coolant, such as cooling air, cooling water, etc., flows.

[0012] The invention and its further features and advantages are explained in greater detail on the basis of exemplary embodiments illustrated schematically in the Figures.

[0013]FIG. 1 shows in schematic representation the precalcination stage of an apparatus for the production of cement clinker with lowered NO_(x) emission.

[0014]FIG. 2 shows the unit II of FIG. 1 isolated in enlarged representation.

[0015] In the cement clinker production line shown in extracted form in FIG. 1, the cement raw meal is fed at the top to a cyclone suspension preheater system, not shown, where it passes through a plurality of cyclone suspension heat exchangers in succession, in combined cocurrent/countercurrent to hot off-gas 10 of the precalcination stage, to be separated from gas stream 10 in the next-to-last (next-to-lowermost) cyclone and, via supply line 11 in raw meal branch 12, split between two material supply lines 13 and 14. After flowing through the uppermost cyclone of the preheater stage of the cement clinker production line, off-gas 10 cooled against the cement raw meal is exhausted by an induced-draft fan, also not shown.

[0016] While raw meal line 13 is confluent into rotary kiln off-gas duct 15, that is, into the off-gas riser of rotary kiln 16, raw meal line 14 is confluent into a tertiary air duct 17, which is supplied with tertiary air from the clinker cooler via tertiary air line 18, which comes from the clinker cooler, not shown, connected downstream of rotary kiln 16. Somewhat below raw meal inlet 13, fuel 19 is admitted to rotary kiln off-gas duct 15 at at least one so-called DeNO_(x) burner, and fuel 20 can likewise be admitted to tertiary air duct 17 roughly in the region of the inlet of raw meal substream 14. The cement raw meal calcined (deacidified) in the precalcination stage is separated from hot off-gas stream 10 in lowermost cyclone 21 and inlet, as extensively (e.g., 95%) calcined cement raw meal 22, to the inlet chamber of the rotary kiln, in the sintering zone of which it is burned to cement clinker.

[0017] In order to form a CO-containing reduction zone in the form of a CO-containing gas strand or CO-containing cloud 23 upwardly adjoining burner 19, which strand or cloud is schematically indicated by right-handed hatching in FIG. 1, fuel 19 admitted into rotary kiln off-gas duct 15 is combusted in rich fashion, that is, with a deficiency of oxygen, with the O₂ content of the kiln off-gas in the rotary kiln off-gas upon exiting the rotary kiln, which content is to be measured in suitable fashion in the rotary kiln inlet chamber, and, if appropriate, with supplemental combustion air. In this CO-containing reduction zone 23, the NO_(x) substantially coming from the rotary kiln firing is reduced, that is, rendered innocuous by decomposition, so that the NO_(x) emission of off-gas 10 of the precalcination stage is minimized. On the other hand, fuel 20 admitted to tertiary air duct 17 can be combusted in lean fashion, that is, with an excess of oxygen. The residual burnout of the CO remaining in reduction zone 23, initially in excess, and of any hydrocarbons that may remain unburned is effected by oxygen from excess tertiary air delivered via tertiary air duct 17 and, if appropriate, at a location higher in the precalcination stage by further tertiary air, which is delivered via a tertiary air branch line 28 and admitted into the precalcination stage. With the aim of intensive mixing of the reactants in order to promote residual burnout, a swirl chamber or mixing chamber 30 can also be arranged in the region of the gooseneck-shaped precalcination stage where the flow is diverted by roughly 180° from ascending pipeline branch 25 into descending pipeline branch 26.

[0018] In order to control the splitting of tertiary air 29 to tertiary air duct 17 and branch line 28 in the desired ratio, control elements such as valves 32 or, respectively, 31 can also be arranged in line 17 or, respectively, in branch line 28.

[0019] As can be inferred from the Figures, a pivoting throttle valve 33 is built into rotary kiln off-gas duct 15 above the at least one DeNO_(x) burner 19 and above raw meal inlet 13, before the confluence of tertiary air line 17, for example roughly in the gore region between rotary kiln off-gas duct 15 and tertiary air duct 17, which throttle valve controls the quantity of rotary kiln off-gas and thus the O₂ content in the kiln off-gas by more-or-less strongly constricting the flow of rotary kiln off-gas in such a way that, as the O₂ content in the rotary kiln off-gas decreases (more strongly throttling position of throttle valve 33), the CO content in reduction zone 23 and thus the effectiveness of the DeNO_(x) reaction is increased, and conversely. The pivoted position of throttle valve 33 here is set as a function of the O₂ content present in the rotary kiln off-gas, which is most expediently measured in inlet chamber 16 a of rotary kiln 16. Thus the measured analysis values of O₂ in the rotary kiln off-gas can lie in a range of roughly 1.0% to 3.0%. In addition to or instead of the measured quantity O₂ content in kiln off-gas, the measured content of CO (e.g., 0.03% to 1.8% in the kiln inlet chamber) and/or of NO_(x) in the off-gas can also be employed for the purpose of controlling the pivoted position of throttle valve 33.

[0020] As can further be inferred from the detailed drawing of FIG. 2, the maximal pivoting range of throttle valve 33, starting from its vertically upwardly pointing position, is a maximal angle of roughly 40°. Throttle valve 33 could, however, also be pivoted into tertiary air duct 17 in order to throttle the quantity of tertiary air and, if appropriate, to increase still further the quantity of kiln off-gas flowing in rotary kiln off-gas duct 15. Throttle valve articulation 34 is arranged on the bottom side of the valve, on which the off-gas impinges. In either case, it can be seen from the drawing that the character of the rotary kiln off-gas flow remains laminar even in the so-called “closed” position of the valve, in which throttle valve 33 still leaves free a sufficiently large free flow cross section in the rotary kiln off-gas duct, so that the length of CO-containing cloud 23, continuing upwardly from the DeNO_(x) burner, and thus also the longest possible residence time of the raw meal for calcination in this reduction zone are preserved.

[0021]FIG. 2 also makes it clear that, according to a further feature of the invention, throttle valve 33 can be designed as a plate-shaped hollow body through which a coolant, such as for example cooling air, flows. In this case, the delivery and discharge of the coolant can be effected via articulation shaft 34. It should also be noted that throttle valve 33 or, respectively, articulation shaft 34 is connected to a control element 35 for the purpose of pivoting or rotation. Initially, an upwardly extending refractory lining 36 can be built into the gore region at the junction of rotary kiln off-gas riser 15 and confluent tertiary air line 17, separating the two lines, which lining advantageously has its upper end inclined somewhat into rotary kiln off-gas duct 15, upwardly extending throttle valve 33 then being articulated on the top side of lining 36. For its reinforcement, refractory lining 36 can also have ducts 37, spaced a distance from one another, through which likewise a coolant can flow for the purpose of extending the service life of lining 36. 

1. Apparatus for thermal processing of raw materials in meal form, particularly in the production of cement clinker from raw meal, which raw meal is preheated in at least one heat exchanger train, in particular cyclone suspension heat exchanger system, through which the off-gas of a rotary kiln (16) flows; calcined in a precalcination stage; and burned in the sintering zone of the rotary kiln (16) to cement clinker, which is cooled in a downstream cooler, the off-gas stream of the rotary kiln and an off-gas stream (tertiary air) of the clinker cooler being used separately or together for the precalcination of the raw meal in the precalcination stage with fuel supply in such fashion that at least one DeNO_(x) burner (19) with rich fuel combustion is arranged in the rotary kiln off-gas duct (15) in order to form a CO-containing reduction zone (23), for the residual burnout of which at least one tertiary air substream is admitted to the rotary kiln off-gas duct (15) at a downstream point, characterized by the following features: a) in the precalcination stage, a pivoting throttle valve (33), controlling the quantity of rotary kiln off-gas and thus the O₂ content in the kiln off-gas, is built into the rotary kiln off-gas duct (15) above the at least one DeNO_(x) burner (19) and above the raw meal inlet (13) ahead of the confluence of the tertiary air substream, b) the throttle valve (33) has its pivoting range in the flow direction of the off-gas, that is, the throttle valve articulation (34) is arranged on the bottom side of the valve, on which the off-gas impinges, so that the character of the flow of rotary kiln off-gas remains laminar in all pivoted positions of the throttle valve (33).
 2. Apparatus according to claim 1, characterized in that the throttle valve (33) is designed as a hollow body through which coolant flows.
 3. Apparatus according to claim 1, characterized in that the throttle valve (33) is arranged in the gore region at the junction of the rotary kiln off-gas duct (15) and the confluent tertiary air line (17).
 4. Apparatus according to claim 31 characterized in that initially, an upwardly extending refractory lining (36) can be built into the gore region at the junction of the rotary kiln off-gas riser (15) and the confluent tertiary air line (17), separating the two lines, on the upper side of which lining the upwardly extending pivoting throttle valve (33), which upwardly prolongs the fixed lining, is articulated.
 5. Apparatus according to one of claims 1 to 4, characterized in that the throttle valve (33) is connected to a control element (35), which through a control action places the throttle valve (33) in a pivoted position more strongly throttling the stream of rotary kiln off-gas as the O₂ content in the rotary kiln off-gas increases, and conversely. 